Abstract:

Disclosed is: (i) a metal injection-molding system, (ii) a metal
injection-molding system including a combining chamber, (iii) a metal
injection-molding system including a first injection mechanism and a
second injection mechanism, (iv) a metal injection-molding system
including a first injection mechanism being co-operable with a second
injection mechanism, (v) a mold of a metal injection-molding system, and
(vi) a method of a metal injection-molding system.

Claims:

1. A metal injection-molding system, comprising:a combining chamber
configured to:(i) receive a molten-metallic alloy and a spacing agent
being injectable under pressure into the combining chamber, the
molten-metallic alloy and the spacing agent combinable, at least in part,
under pressure in the combining chamber, and(ii) convey, under pressure,
the molten-metallic alloy and the spacing agent toward a mold, the
molten-metallic alloy combined with the spacing agent being solidifiably
formable into a molded-foamed-metallic article in the mold.

2. The metal injection-molding system of claim 1, wherein the combining
chamber includes a mixing element configured to mix the molten-metallic
alloy and the spacing agent.

3. The metal injection-molding system of claim 1, wherein the
molten-metallic alloy and the spacing agent are injectable under pressure
from injection mechanisms respectively that are coupled to the combining
chamber.

4. The metal injection-molding system of claim 1, wherein the combining
chamber is configured to communicate, under pressure, the molten-metallic
alloy and the spacing agent to a mold gate leading to a mold cavity
defined by a mold body of the mold, the molten-metallic alloy and the
spacing agent solidifying and forming the molded-foamed-metallic article
in the mold cavity.

5. The metal injection-molding system of claim 1, wherein the combining
chamber includes:a combining valve configured to: (i) couple to a first
injection mechanism, and (ii) couple to a second injection mechanism;
anda conduit configured to: (i) couple to the combining valve, and (ii)
couple to a mold gate leading to a mold cavity defined by the mold.

6. The metal injection-molding system of claim 1, wherein the combining
chamber includes:a combining valve having a non-flow state and a flow
state,in the non-flow state, the combining valve is configured to: (i)
not receive the molten-metallic alloy and the spacing agent from
respective injection mechanisms, andin the flow state, the combining
valve is configured to: (i) receive the molten-metallic alloy and the
spacing agent from the respective injection mechanisms, the
molten-metallic alloy and the spacing agent combining, at least in part,
in the combining valve; anda conduit configured to: (i) receive the
molten-metallic alloy and the spacing agent from the combining valve, and
(ii) communicate the molten-metallic alloy and the spacing agent to a
mold gate leading to a mold cavity defined by the mold.

7. The metal injection-molding system of claim 1, wherein the combining
chamber includes:a combining valve configured to: (i) couple to injection
mechanisms;a channel configured to couple to the combining valve;a
shooting pot valve configured to couple to the channel;a shooting pot
configured to couple to the shooting pot valve; anda conduit configured
to couple to: (i) the shooting pot valve, and (ii) a mold gate leading to
a mold cavity defined by the mold.

8. The metal injection-molding system of claim 1, wherein the combining
chamber includes:a combining valve having a non-flow state and a flow
state,in the non-flow state, the combining valve is configured to: (i)
not receive the molten-metallic alloy and the spacing agent from
respective injection mechanisms,in the flow state, the combining valve is
configured to: (i) receive the molten-metallic alloy and the spacing
agent from the respective injection mechanisms, the molten-metallic alloy
and the spacing agent combining, at least in part, in the combining
valve;a channel configured to receive the molten-metallic alloy and the
spacing agent from the combining valve;a shooting pot valve having a
first valve state and a second valve state, in the first valve state, the
shooting pot valve is configured to not receive the molten-metallic alloy
and the spacing agent from the channel, and in the second valve state,
the shooting pot valve is configured to receive the molten-metallic alloy
and the spacing agent from the channel;a shooting pot configured to
receive the molten-metallic alloy and the spacing agent from the shooting
pot valve once the shooting pot valve is placed in the second valve
state, and the shooting pot valve is configured to disconnect the channel
from the shooting pot once the shooting pot valve is placed in the first
valve state; anda conduit configured to: (i) receive the molten-metallic
alloy and the spacing agent from the shooting pot valve once the shooting
pot valve is placed in the first valve state, and (ii) communicate the
molten-metallic alloy and the spacing agent to a mold gate leading to a
mold cavity defined by the mold.

9. The metal injection-molding system of claim 1, wherein the combining
chamber includes:a combining valve configured to: (i) couple to injection
mechanisms, and (ii) couple to a shooting pot; anda conduit coupled to:
(i) the combining valve, and (ii) a mold gate leading to a mold cavity
defined by the mold.

10. The metal injection-molding system of claim 1, wherein the combining
chamber includes:a combining valve having a first state and a second
state,in the first state, the combining valve is configured to: (i)
receive the molten-metallic alloy and the spacing agent from respective
injection mechanisms, the molten-metallic alloy and the spacing agent
combining, at least in part, to form the molten-metallic alloy and the
spacing agent in the combining valve, and (iii) transmit the
molten-metallic alloy and the spacing agent to a shooting pot,in the
second state, the combining valve is configured to: (i) not receive the
molten-metallic alloy and the spacing agent from the respective injection
mechanisms, and (ii) permit the shooting pot to shoot the molten-metallic
alloy and the spacing agent back into the combining valve; anda conduit
configured to: (i) communicate the molten-metallic alloy and the spacing
agent, under pressure, from the combining valve to a mold gate once the
combining valve is placed in the second state, the mold gate leads to a
mold cavity defined by the mold.

11. The metal injection-molding system of claim 1, wherein the combining
chamber includes:a combining valve configured to: (i) couple to injection
mechanisms, and (ii) couple to a mold gate leading to a mold cavity
defined by the mold.

12. The metal injection-molding system of claim 1, wherein the combining
chamber includes:a combining valve having a first state and a second
state,in the first state, the combining valve is configured to: (i)
receive the molten-metallic alloy and the spacing agent from respective
injection mechanisms, the molten-metallic alloy and the spacing agent and
combining, at least in part, in the combining valve, and (iii)
communicate the molten-metallic alloy and the spacing agent to a mold
gate leading to a mold cavity defined by the mold, andin the second
state, the combining valve is configured to: (i) not receive the
molten-metallic alloy and the spacing agent from the respective injection
mechanisms.

13. The metal injection-molding system of claim 1, wherein the metal
injection-molding system includes a metal-injection molding system.

14. The metal injection-molding system of claim 1, wherein the combining
chamber includes:a combining valve configured to: (i) couple to
respective injection mechanisms; anda conduit configured to: (i) couple
to the combining valve, and (ii) couple to a mold gate leading to a mold
cavity defined by the mold.

15. The metal injection-molding system of claim 1, wherein the combining
chamber includes:a combining valve having a non-flow state and a flow
state, in the non-flow state, the combining valve is configured to not
receive the molten-metallic alloy and the spacing agent from respective
injection mechanisms, and in the flow state, the combining valve is
configured to receive the molten-metallic alloy and the spacing agent
from the respective injection mechanisms, the molten-metallic alloy and
the spacing agent combining, at least in part, in the combining valve;a
channel configured to receive the molten-metallic alloy and the spacing
agent from the combining valve;a shooting pot valve having a first valve
state and a second valve state, in the first valve state, the shooting
pot valve is configured to not receive the molten-metallic alloy and the
spacing agent from the channel, and in the second valve state, the
shooting pot valve is configured to receive the molten-metallic alloy and
the spacing agent from the channel;a shooting pot configured to receive
the molten-metallic alloy and the spacing agent from the shooting pot
valve once the shooting pot valve is placed in the second valve state,
and the shooting pot valve is configured to disconnect the channel from
the shooting pot once the shooting pot valve is placed in the first valve
state; anda conduit configured to: (i) receive the molten-metallic alloy
and the spacing agent from the shooting pot valve once the shooting pot
valve is placed in the first valve state, and (ii) communicate the
molten-metallic alloy and the spacing agent to a mold gate leading to a
mold cavity defined by the mold.

16. The metal injection-molding system of claim 1, wherein the combining
chamber includes:a combining valve configured to: (i) couple to
respective injection mechanisms, and (ii) couple to a shooting pot; anda
conduit coupled to: (i) the combining valve, and (ii) a mold gate leading
to a mold cavity defined by the mold.

17. The metal injection-molding system of claim 1, wherein the combining
chamber includes:a combining valve having a first state and a second
state, in the first state, the combining valve is configured to: (i)
receive the molten-metallic alloy and the spacing agent from respective
injection mechanisms, the molten-metallic alloy and the spacing agent
combining, at least in part, in the combining valve, and (iii) transmit
the molten-metallic alloy and the spacing agent to a shooting pot, and in
the second state, the combining valve is configured to: (i) not receive
the molten-metallic alloy and the spacing agent from the respective
injection mechanisms, and (iii) permit the shooting pot to shoot the
molten-metallic alloy and the spacing agent back into the combining
valve; anda conduit configured to: (i) communicate the molten-metallic
alloy and the spacing agent, under pressure, from the combining valve to
a mold gate once the combining valve is placed in the second state, the
mold gate leading to a mold cavity defined by the mold.

18. The metal injection-molding system of claim 1, wherein the combining
chamber includes:a combining valve configured to: (i) couple to
respective injection mechanisms, and (iii) couple to a mold gate leading
to a mold cavity defined by the mold.

19. The metal injection-molding system of claim 1, wherein the combining
chamber includes:a combining valve having a first state and a second
state, in the first state, the combining valve is configured to: (i)
receive the molten-metallic alloy and the spacing agent from respective
injection mechanisms, the molten-metallic alloy and the spacing agent
combining, at least in part, in the combining valve, and (iii)
communicates the molten-metallic alloy and the spacing agent to a mold
gate leading to a mold cavity defined by the mold, and in the second
state, the combining valve is configured to: (i) not receive the
molten-metallic alloy and the spacing agent from the respective injection
mechanisms.

20. The metal injection-molding system of claim 1, wherein the combining
chamber is configured to communicate, under pressure, the molten-metallic
alloy and the spacing agent to a mold gate leading to a mold cavity
defined by the mold, the molten-metallic alloy and the spacing agent
solidifying and forming the molded-foamed-metallic article in the mold
cavity, the molded-foamed-metallic article being releasable from the mold
after: (i) a clamping mechanism has ceased applying a clamp tonnage
between a movable platen and a stationary platen, and (ii) the movable
platen has been moved away from the stationary platen so as to separate a
stationary mold portion from a movable mold portion, the stationary mold
portion being supported by the stationary platen, and the movable mold
portion being supported by the movable platen.

21. The metal injection-molding system of claim 1, wherein the combining
chamber includes:a hot runner, including:a manifold, having:(i) switching
valves coupled to respective injection mechanisms so as to receive the
molten-metallic alloy and the spacing agent from the respective injection
mechanisms;(ii) shooting pots coupled to the switching valves
respectively; and(iii) a combining valve coupled to the shooting pots and
also coupled to a mold gate leading to a mold cavity defined by the mold.

22. The metal injection-molding system of claim 21, wherein the shooting
pots each respectively includes:pressure chambers being fillable with a
pressurizable fluid;accumulation chambers; andpistons that are each
slidably movable between the pressure chambers respectively and the
accumulation chambers respectively.

23. The metal injection-molding system of claim 22, wherein once the
combining valve and the switching valves are placed in a non-flow state,
and the accumulation chambers are de-pressurized so as to permit the
pistons to be movable, the respective injection mechanisms process and
prepare the molten-metallic alloy and the spacing agent.

24. The metal injection-molding system of claim 22, wherein once the
combining valve is placed in a non-flow state and the switching valves
are placed in a flow state, and the respective injection mechanisms
inject the molten-metallic alloy and the spacing agent respectively into
the accumulation chambers of the shooting pots respectively, and the
pistons are moved into the pressure chambers respectively so as to
displace the pressurizable fluid out from the pressure chambers.

25. The metal injection-molding system of claim 22, wherein once the
switching valves are placed in a non-flow state, the combining valve is
placed in a flow state, and the pressure chambers are pressurized, then
(i) the pistons are moved into the accumulation chambers respectively so
as to inject or push the molten-metallic alloy and the spacing agent
respectively into the combining valve, and (ii) the molten-metallic alloy
and the spacing agent become combined, at least in part in the combining
valve, and then the molten-metallic alloy and the spacing agent is pushed
under pressure into the mold gate.

26. The metal injection-molding system of claim 1, wherein the combining
chamber includes:a hot runner, including:a manifold, having:(i) shooting
pots coupled to respective injection mechanisms so as to receive the
molten-metallic alloy and the spacing agent from the respective injection
mechanisms; and(iii) a combining valve coupled to the shooting pots and
also coupled to a mold gate leading to a mold cavity defined by the mold.

27. The metal injection-molding system of claim 26, wherein the shooting
pots each respectively include:pressure chambers being fillable with a
pressurizable fluid;accumulation chambers; andpistons that are slidably
movable between the pressure chambers and the accumulation chambers.

28. The metal injection-molding system of claim 27, wherein once the
combining valve is placed in a non-flow state, the respective injection
mechanisms accumulate and then inject the molten-metallic alloy and the
spacing agent respectively into the accumulation chambers.

29. The metal injection-molding system of claim 27, wherein:once the
molten-metallic alloy and the spacing agent are received into the
accumulation chambers respectively, screws of the respective injection
mechanisms maintain their positions so as to prevent flow of the
molten-metallic alloy and the spacing agent back into the respective
injection mechanisms, andonce the combining valve is placed in a flow
state, then the pressure chambers are pressurized so as to move the
pistons into the accumulation chambers respectively so as to inject the
molten-metallic alloy and the spacing agent respectively from the
accumulation chambers into the combining valve.

30. The metal injection-molding system of claim 1, wherein the combining
chamber includes:a hot runner, including:a manifold, having:a combining
valve coupled to injection mechanisms; andnozzles coupled to the
combining valve, and also coupled to respective mold gates leading to
mold cavities defined by a mold body of the mold, and in operation, the
molten-metallic alloy and the spacing agent combine, at least in part, in
the combining valve and the nozzles.

31. A metal injection-molding system, comprising:a first injection
mechanism configured to process a molten-metallic alloy; anda second
injection mechanism configured to process a spacing agent, the first
injection mechanism and the second injection mechanism configured to
couple to a combining chamber configured to:(i) receive the
molten-metallic alloy and the spacing agent being injectable under
pressure into the combining chamber, the molten-metallic alloy and the
spacing agent combining, at least in part, under pressure in the
combining chamber, and(ii) convey, under pressure, the molten-metallic
alloy and the spacing agent to a mold, the molten-metallic alloy combined
with the spacing agent being solidifiably formable into a
molded-foamed-metallic article in the mold.

32. A metal injection-molding system, comprising:a first injection
mechanism configured to process a molten-metallic alloy, the first
injection mechanism being co-operable with a second injection mechanism
configured to process a spacing agent, the first injection mechanism and
the second injection mechanism configured to couple to a combining
chamber configured to:(i) receive the molten-metallic alloy and the
spacing agent being injectable under pressure into the combining chamber,
the molten-metallic alloy and the spacing agent combining, at least in
part, under pressure in the combining chamber, and(ii) convey, under
pressure, the molten-metallic alloy and the spacing agent to a mold, the
molten-metallic alloy combined with the spacing agent being solidifiably
formable into a molded-foamed-metallic article in the mold.

33. A metal injection-molding system, comprising:a first injection
mechanism configured to process a molten-metallic alloy;a second
injection mechanism configured to process a spacing agent;a stationary
platen configured to support a stationary mold portion of a mold;a
movable platen configured to move relative to the stationary platen, and
configured to support a movable mold portion of the mold, the stationary
mold portion and the movable mold portion forming a mold cavity once the
movable platen is made to move toward the stationary platen sufficiently
enough as to abut the stationary mold portion against the movable mold
portion, the stationary mold portion defining a mold gate leading to the
mold cavity;a clamping mechanism coupled to the stationary platen and the
movable platen, and configured to apply a clamp tonnage between the
stationary platen and the movable platen; anda combining chamber
configured to:(i) receive the molten-metallic alloy and the spacing agent
being injectable under pressure into the combining chamber, the
molten-metallic alloy and the spacing agent combining, at least in part,
under pressure in the combining chamber, and(ii) convey, under pressure,
the molten-metallic alloy and the spacing agent to the mold, the
molten-metallic alloy combined with the spacing agent being solidifiably
formable into a molded-foamed-metallic article in the mold.

34. An article made by usage of a metal injection-molding system of claim
1.

35. A method of a metal injection-molding system, comprising:receiving, in
a combining chamber, a molten-metallic alloy and a spacing agent being
injectable under pressure into the combining chamber, the molten-metallic
alloy and the spacing agent combining, at least in part, under pressure
in the combining chamber, andconveying, under pressure, the
molten-metallic alloy and the spacing agent to a mold, the
molten-metallic alloy combined with the spacing agent being solidifiably
formable into a molded-foamed-metallic article in the mold.

36. The method of the metal injection-molding system of claim 35, further
comprising:communicating, under pressure, the molten-metallic alloy and
the spacing agent to a mold gate leading to a mold cavity defined by the
mold, the molten-metallic alloy and the spacing agent solidifying and
forming the molded-foamed-metallic article in the mold cavity.

37. The method of the metal injection-molding system of claim 35, further
comprising:communicating the molten-metallic alloy and the spacing agent,
under pressure, from the combining chamber to a mold gate leading to a
mold cavity defined by the mold, the molten-metallic alloy and the
spacing agent solidifying and forming the molded-foamed-metallic article
in the mold cavity.

38. A metal injection-molding process, comprising:injecting, under
pressure, a molten-metallic alloy and a spacing agent into a mold, the
molten-metallic alloy combined with the spacing agent being solidifiably
formable into a molded-foamed-metallic article in the mold.

39. A metal injection-molding process, comprising:a receiving operation,
including receiving a solidified-metallic alloy and a spacing agent;a
heating operation, including heating the solidified-metallic alloy
associated with the receiving operation above a solidus temperature of
the solidified-metallic alloy, the solidified-metallic alloy becoming a
molten-metallic alloy;a combining operation, including combining the
molten-metallic alloy associated with the heating operation with the
spacing agent associated with the receiving operation; andan injecting
operation, including injecting, under pressure, the molten-metallic alloy
and the spacing agent into a mold, the molten-metallic alloy combined
with the spacing agent being solidifiably formable into a
molded-foamed-metallic article in the mold.

40. The metal injection-molding process of claim 39, wherein the spacing
agent combined with the molten-metallic alloy so that the molten-metallic
alloy and the spacing agent solidifies into the molded-foamed-metallic
article.

47. The metal injection-molding process of claim 39, wherein the spacing
agent includes:a blowing agent, anda parent material, the blowing agent
and the parent material are activated by heat so as to create foam
responsive to the blowing agent experiencing a drop in pressure.

51. The metal injection-molding process of claim 39, wherein the
molten-metallic alloy is heated above the solidus temperature of the
molten-metallic alloy but below a liquidus temperature of the
molten-metallic alloy.

52. The metal injection-molding process of claim 39, wherein the
molten-metallic alloy is heated above a liquidus temperature of the
molten-metallic alloy.

57. A material input used by the metal injection-molding process of claim
39.

58. An article made by the metal injection-molding process of claim 39.

59. A metal injection-molding system operable according to the metal
injection-molding process of claim 39.

60. A metal injection-molding system, comprising:receiving means
configured to implement a receiving operation, including receiving a
solidified-metallic alloy and a spacing agent;heating means configured to
implement a heating operation, including heating the solidified-metallic
alloy associated with the receiving operation above a solidus temperature
of the solidified-metallic alloy, the solidified-metallic alloy becoming
a molten-metallic alloy;combining means configured to implement a
combining operation, including combining the molten-metallic alloy
associated with the heating operation with the spacing agent associated
with the receiving operation; andinjection means configured to implement
an injecting operation, including injecting, under pressure, the
molten-metallic alloy and the spacing agent into a mold, and the
molten-metallic alloy combined with the spacing agent being solidifiably
formable into a molded-foamed-metallic article in the mold.

61. The metal injection-molding system of claim 60, wherein:the receiving
means is coupled to the injection means;the heating means is coupled to
the injection means;the injection means is coupled to the combining
means; andthe combining means is couplable to the mold.

62. An article made by the metal injection-molding system of claim 60.

Description:

TECHNICAL FIELD

[0001]The present invention generally relates to, but is not limited to,
molding systems, and more specifically the present invention relates to,
but is not limited to, (i) a metal injection-molding system, (ii) a metal
injection-molding system including a combining chamber, (iii) a metal
injection-molding system including a first injection mechanism and a
second injection mechanism, (iv) a metal injection-molding system
including a first injection mechanism being co-operable with a second
injection mechanism, (v) a mold of a metal injection-molding system, and
(vi) a method of a metal injection-molding system.

[0003]U.S. Pat. No. 5,865,237 (Inventor: SCHORGHUBER et al; Published:
1999-Feb.-02) discloses production of molded foamed metal parts, in which
a compacted powder metallurgical preform is foamed by heating in a
chamber and the foam charge is injected into a mold.

[0005]U.S. Pat. No. 6,733,722 (Inventor: SINGER et al; Published:
2004-May-11) discloses production of a molded body from a foamed metal
that includes feeding two powders in non-compact form to an extruder,
injecting powder mixture into the mold and releasing the pressure so that
the mold is completely filled with foamed metal.

[0006]PCT Patent Number WO/04108976A2 (Inventor: KORNER et al; Published:
2004-Dec.-16) discloses foamed metal molding production, that includes
adding foaming agent to molten metal after leaving supply vessel and
before entry into a mold cavity. Also disclosed is a method for producing
a metal foam body, whereby a molten metal is prepared and introduced into
a reservoir, and the molten metal is injected into a mold cavity
surrounded by a mold, via a line connecting the reservoir to the mold.
The aim is to create a foam structure only in the core of the metal foam
body. To this end, a blowing agent is added to the metal melt, once it
has left the reservoir and before it enters the mold cavity.

[0007]U.S. Pat. No. 6,866,084 (Inventor: ASHOLT et al; Published:
2005-Mar.-15) discloses a method and means for producing molded bodies of
a metal foam, in particular an aluminum foam. The method involves the use
of mold having a cavity and at least one entrance opening. The mold is
filled with a metal foam in a manner where the entrance opening of the
mold is submerged into a metal melt and the melt is caused to foam inside
the mold and fill its cavity.

[0009]U.S. Pat. No. 6,915,834 (Inventor: KNOTT et al; Published:
2005-Jul.-12) discloses production of a metal foam that includes
inserting the molten metal into a mold hollow chamber, and foaming with a
propellant which is solid at room temperature. Also disclosed is a
process for producing a metal foam and to a metal body produced using the
process. The object is achieved by a process for producing the metal foam
by adding a blowing agent to a metal melt, wherein the metal melt is: (i)
introduced into the die cavity of a metal die-casting machine, and is
(ii) foamed using a blowing agent, which releases gases and is solid at
room temperature.

[0010]U.S. Pat. No. 6,998,535 (Inventor: NICHOL; Published: 2006-Feb.-14)
discloses a method for casting articles from a metal foam, a molten metal
bath and a foam-forming means. The foam is drawn into a ladle, within a
heated chamber, which transports a foam sample to a mold. The ladle
deposits the foam sample into the mold and the mold is closed. Once
cooled and hardened the formed article is removed. The system includes a
molten metal bath, a heated foam collecting chamber, a ladle for drawing
a sample of the foam and for transporting the sample to a mold.

[0012]U.S. Pat. No. 7,175,689 (Inventor: DOBESBERGER et al; Published:
2007-Feb.-13) discloses a process for producing a lightweight molded
part, comprising introducing a gas into a particle-containing, molten
metal to produce a metal foam having voids with a monomodal distribution
of their dimensions, introducing the metal foam into a casting die and
compressing it therein essentially under all-round pressure; and the
molded part made by this process.

[0013]U.S. Pat. No. 7,195,662 (Inventor: DOBESBERGER et al; Published:
2007-Mar.-27) discloses a device for feeding gas in a melt of foamable
metal by means of at least one pipe for producing metal foam. The gas
insertion pipe projects inwardly into the melt and at the projecting end
has a gas outlet having a cross-sectional area of 0.006 to 0.2
millimeters (mm) squared, and a pipe face area of less than 4.0 mm
squared. A flowable metal foam has gas bubbles defined by walls of a
liquid metal matrix with solid reinforcing particles, and the diameter of
the largest gas bubbles divided by that of the smallest gas bubbles is
less than 2.5.

[0014]A technical article (Title: METALLIC FOAMS--ULTRA LIGHT MATERIALS
FOR STRUCTURAL APPLICATIONS; Author: FRANTIEK SIMANCIK; Technical Journal
Name: INZYNIERIA MATERIALOWA Nr. 5/2001; Pages: 823 to 828) discloses, in
the Abstract, the following: metallic foams are relatively unknown
structural materials, however with enormous future potential for
applications where lightweight combined with high stiffness and
acceptable manufacturing costs are of prime interest The performance of
metallic foams, in particular those made of aluminum, in various
prototypes, such as foamed panels, sandwiches, complex 3-D-parts, foamed
hollow profiles as well as castings with foamed cores, has been discussed
with respect to the expected and achieved goals. The important
contributions of aluminum foam to the improvement of the products
properties are highlighted and most promising utilization is suggested.

[0015]A technical article (Title: PRODUCTION AND PROPERTIES OF FOAMED
MAGNESIUM; Authors: Fr.-W. BACH, 0. BORMAUN, P. WILK, R. KUCHARSKI;
Journal Title: CELLULAR METALS AND POLYMERS 2004, pages 77 to 80, edited
by R. F. Singer; C. Korner, V. Altstadt, Fragezeichenverlag, Furth, Long
ISBN number 8585858585) discloses, in the Abstract, results from the
priority program "Cellular Metals" of the Deutsche Forschungsgemeinschaft
(DFG SPP 1075). Two processes for the production of foams and sponges
basing on magnesium are presented and discussed concerning their
producibility and their applications. The powder metallurgical route for
the production of metallic foams basing on aluminum is well examined
since some decades but foamed parts basing on magnesium could not be
produced yet. The discussion of the foamability of magnesium alloys leads
to a sintering process which enhances the foamability at the beginning of
the foaming process and finally leads to foamed magnesium cylinders with
40 mm in diameter. Relatively easy in the production but appropriate only
for small open cell sponges is the infiltration process using salt grains
as place holder. The molten magnesium is forced by vacuum to infiltrate
the salt grains which are dissolved in sodium hydroxide solution after
machining. A method which applies mechanical vibration for grain fining
of the bulk material and improving the infiltration process is adopted.

SUMMARY

[0016]According to a first aspect of the present invention, there is
provided a metal injection-molding system, including a combining chamber
configured to: (i) receive a molten-metallic alloy and a spacing agent
being injectable under pressure into the combining chamber, the
molten-metallic alloy and the spacing agent combinable, at least in part,
under pressure in the combining chamber, and (ii) convey, under pressure,
the molten-metallic alloy and the spacing agent toward a mold, the
molten-metallic alloy combined with the spacing agent being solidifiably
formable into a molded-foamed-metallic article in the mold.

[0017]According to a second aspect of the present invention, there is
provided a metal injection-molding system, including a first injection
mechanism configured to process a molten-metallic alloy, and a second
injection mechanism configured to process a spacing agent, the first
injection mechanism and the second injection mechanism configured to
couple to a combining chamber configured to: (i) receive a
molten-metallic alloy and a spacing agent being injectable under pressure
into the combining chamber, the molten-metallic alloy and the spacing
agent combining, at least in part, under pressure in the combining
chamber, and (ii) convey, under pressure, the molten-metallic alloy and
the spacing agent to a mold, the molten-metallic alloy combined with the
spacing agent being solidifiably formable into a molded-foamed-metallic
article in the mold.

[0018]According to a third aspect of the present invention, there is
provided a metal injection-molding system, including a first injection
mechanism configured to process a molten-metallic alloy, the first
injection mechanism being co-operable with a second injection mechanism
configured to process a spacing agent, the first injection mechanism and
the second injection mechanism configured to couple to a combining
chamber configured to: (i) receive a molten-metallic alloy and a spacing
agent being injectable under pressure into the combining chamber, the
molten-metallic alloy and the spacing agent combining, at least in part,
under pressure in the combining chamber, and (ii) convey, under pressure,
the molten-metallic alloy and the spacing agent to a mold, the
molten-metallic alloy combined with the spacing agent being solidifiably
formable into a molded-foamed-metallic article in the mold.

[0019]According to a fourth aspect of the present invention, there is
provided a metal injection-molding system, including a first injection
mechanism configured to process a molten-metallic alloy, a second
injection mechanism configured to process a spacing agent, a stationary
platen configured to support a stationary mold portion of a mold, a
movable platen configured to move relative to the stationary platen, and
configured to support a movable mold portion of the mold, the stationary
mold portion and the movable mold portion forming a mold cavity once the
movable platen is made to move toward the stationary platen sufficiently
enough as to abut the stationary mold portion against the movable mold
portion, the stationary mold portion defining a mold gate leading to the
mold cavity, a clamping mechanism coupled to the stationary platen and
the movable platen, and configured to apply a clamp tonnage between the
stationary platen and the movable platen, and a combining chamber
configured to: (i) receive a molten-metallic alloy and a spacing agent
being injectable under pressure into the combining chamber, the
molten-metallic alloy and the spacing agent combining, at least in part,
under pressure in the combining chamber, and (ii) convey, under pressure,
the molten-metallic alloy and the spacing agent to a mold, the
molten-metallic alloy combined with the spacing agent being solidifiably
formable into a molded-foamed-metallic article in the mold.

[0020]According to a fifth aspect of the present invention, there is
provided a method of a metal injection-molding system, including: (i)
receiving, in a combining chamber, a molten-metallic alloy and a spacing
agent being injectable under pressure into the combining chamber, the
molten-metallic alloy and the spacing agent combining, at least in part,
under pressure in the combining chamber, and (ii) conveying, under
pressure, the molten-metallic alloy and the spacing agent to a mold, the
molten-metallic alloy combined with the spacing agent being solidifiably
formable into a molded-foamed-metallic article in the mold.

[0021]According to a sixth aspect of the present invention, there is
provided a metal injection-molding process, including injecting, under
pressure, a molten-metallic alloy and a spacing agent into a mold, the
molten-metallic alloy combined with the spacing agent being solidifiably
formable into a molded-foamed-metallic article in the mold.

[0022]According to a seventh aspect of the present invention, there is
provided a metal injection-molding process, including: (i) a receiving
operation, including receiving a solidified molten-metallic alloy and a
spacing agent, (ii) a heating operation, including heating the solidified
molten-metallic alloy associated with the receiving operation above a
solidus temperature of the solidified molten-metallic alloy, the
solidified molten-metallic alloy becoming a molten-metallic alloy, (iii)
a combining operation, including combining the molten-metallic alloy
associated with the heating operation with the spacing agent associated
with the receiving operation, and (iv) an injecting operation, including
injecting, under pressure, the molten-metallic alloy and the spacing
agent into a mold, the molten-metallic alloy combined with the spacing
agent being solidifiably formable into a molded-foamed-metallic article
in the mold.

[0023]According to an eighth aspect of the present invention, there is
provided a metal injection-molding system, including: (i) receiving means
configured to implement a receiving operation, including receiving a
solidified molten-metallic alloy and a spacing agent, (ii) heating means
configured to implement a heating operation, including heating the
solidified molten-metallic alloy associated with the receiving operation
above a solidus temperature of the solidified molten-metallic alloy, the
solidified molten-metallic alloy becoming a molten-metallic alloy, (iii)
combining means configured to implement a combining operation, including
combining the molten-metallic alloy associated with the heating operation
with the spacing agent associated with the receiving operation, and (iv)
injection means configured to implement an injecting operation, including
injecting, under pressure, the molten-metallic alloy and the spacing
agent into a mold, the molten-metallic alloy and the spacing agent into a
mold, the molten-metallic alloy combined with the spacing agent being
solidifiably formable into a molded-foamed-metallic article in the mold.

[0024]A technical effect, amongst other technical effects, of the aspects
of the present invention is improved operation of a molding system for
manufacturing articles molded of metallic alloys.

DESCRIPTION OF THE DRAWINGS

[0025]A better understanding of the non-limiting embodiments of the
present invention (including alternatives and/or variations thereof) may
be obtained with reference to the detailed description of the
non-limiting embodiments along with the following drawings, in which:

[0026]FIG. 1 depicts a schematic representation of a metal
injection-molding system according to a first non-limiting embodiment;

[0027]FIG. 2 depicts a schematic representation of a metal
injection-molding system according to a second non-limiting embodiment;

[0028]FIG. 3 depicts a schematic representation of a metal
injection-molding system according to a third non-limiting embodiment;

[0029]FIG. 4 depicts a schematic representation of a metal
injection-molding system according to a fourth non-limiting embodiment;

[0030]FIG. 5 depicts a schematic representation of a metal
injection-molding system according to a fifth non-limiting embodiment;

[0031]FIG. 6 depicts a schematic representation of a metal
injection-molding system according to a sixth non-limiting embodiment;

[0032]FIG. 7 depicts a schematic representation of a metal
injection-molding system according to a seventh non-limiting embodiment;

[0033]FIG. 8 depicts a schematic representation of a metal
injection-molding process 10 according to the eighth non-limiting
embodiment; and

[0034]FIG. 9 depicts a schematic representation of a metal
injection-molding system 500 operable according to the metal
injection-molding process 10 of FIG. 8.

[0035]The drawings are not necessarily to scale and are sometimes
illustrated by phantom lines, diagrammatic representations and
fragmentary views. In certain instances, details that are not necessary
for an understanding of the embodiments or that render other details
difficult to perceive may have been omitted.

[0090]FIG. 1 depicts the schematic representation of the metal
injection-molding system 100 (hereafter referred to as the "system 100")
according to the first non-limiting embodiment. Preferably, the system
100 includes a metal-injection molding system 101. The system 100 may
include some components that are known to persons skilled in the art, and
these known components will not be described here; these known components
are described, at least in part, in the following text books (by way of
example): (i) "Injection Molding Handbook" by Osswald/Turng/Gramann
(ISBN: 3-446-21669-2; publisher: Hanser), (ii) "Injection Molding
Handbook" by Rosato and Rosato (ISBN: 0-412-99381-3; publisher: Chapman &
Hill), and/or (iii) "Injection Molding Systems" 3rd Edition by
Johannaber (ISBN 3-446-17733-7).

[0091]According to the first non-limiting embodiment, the system 100
includes a first injection mechanism 110 (hereafter referred to as the
"mechanism 110") that is configured to process a molten-metallic alloy
112 (hereafter referred to as the "alloy 112"). The system 100 also
includes a second injection mechanism 114 (hereafter referred to as the
"mechanism 114") that is configured to process a spacing agent 116. The
combination of the alloy 112 and the spacing agent 116 will be, from time
to time, referred to as the "inputs" for the sake of simplifying the
detailed description. Once the spacing agent 116 is combined with the
alloy 112, the alloy 112 and the spacing agent 116 may solidify (in a
mold 104) into a molded-foamed-metallic article 124 (hereafter referred
to as the "article 124"). According to non-limiting variants, the spacing
agent 116 includes any one of (for example, but not limited to): (i) a
gas, (ii) a non-reactive solid being non-reactive with the alloy 112,
and/or (iii) a reactive solid being reactive with the alloy 112. Examples
of the spacing agent 116 are described in technical articles, titled: (i)
METALLIC FOAMS--ULTRA LIGHT MATERIALS FOR STRUCTURAL APPLICATIONS;
Author: FRANTIEK SIMANCIK; Technical Journal Name: INZYNIERIA MATERIALOWA
Nr. 5/2001, and (ii) PRODUCTION AND PROPERTIES OF FOAMED MAGNESIUM;
Authors: Fr.-W. BACH, 0. BORMAUN, P. WILK, R. KUCHARSKI; Journal Title:
CELLULAR METALS AND POLYMERS 2004; edited by R. F. Singer; C. Korner, V.
Altstadt, Fragezeiche). The spacing agent 116 may also be called a
foaming agent, in that by combining the spacing agent 116 with the alloy
112, an article may be molded to form a molded-foamed-metallic article,
which includes "spaces" primarily located in the solidified alloy of the
molded article; the spaces in the molded article may also be called
"voids" or the spaces may contain a material that is lighter (in weight
and/or density) than (the weight and/or density of) the solidified alloy.
According to a non-limiting variant, the spacing agent 116 includes
hollow-sphere structures that are made of a material being different than
the alloy 112. The hollow-sphere structures do not (for the most part)
melt in the alloy 112. The hollow-sphere structures may be pre-produced
by different techniques. It is possible to manufacture hollow spheres
with: (i) a diameter in a range from about 1 to about 10 millimeters
(mm), and/or (ii) a mantle thicknesses from about 20 to about 50
micrometers (μm). The hollow-sphere structures may be manufactured in
principle by sintering, soldering and/or sticking. Hollow-sphere
structures on iron basis are producible in a far density range, from
about 0.2 to 1.5 grams per cubic centimeter (g/cm3). The operational
areas lie for example in lightweight construction, in heat and acoustic
noise insulation, as crash absorber or carrier material for functional
applications, etc. Details regarding the hollow spheres may be obtained
from Dr.-Ing. Guenter Stephani at the Fraunhofer-Institut fur
Fertigungstechnik und Angewandte Materialforschung, Institutsteil Dresden
IFAM-DD, Winterbergstr. 28, 01277 Dresden, Germany.

[0092]There are several options (but not limited thereto) available for
manufacturing the article 124: (i) injecting a mixture of a flowable
alloy (either a molten, liquid metal or a semisolid metal) and a gas
(which is an example of a spacing agent 116) into a mold, and the mixture
solidifies in the mold to form the foamed alloy, (ii) injecting a mixture
of a flowable alloy (either a molten, liquid metal or a semisolid metal)
and a space holder (which is an example of a spacing agent 116), in which
examples of the space holder are: organic granules and/or inorganic
granules which may remain in the solidified metallic foamed alloy or may
be removed from the solidified metallic foamed alloy by a thermal
treatment and/or a chemical treatment, (iii) injecting a mixture of a
flowable alloy (either a molten, liquid metal or a semisolid metal) and
hollow spheres (which is an example of a spacing agent 116), and/or (iv)
injecting a mixture of a flowable alloy (either a molten, liquid metal or
a semisolid metal) and a blowing agent (which is an example of a spacing
agent 116), in which the blowing agent decomposes under the influence of
heat and releases gas which propels the foaming process. Under option
(iv), the blowing agent is mixed with a parent material, the blowing
agent and the parent material are activated by heat so as to create foam
responsive to the blowing agent experiencing a drop in pressure. In other
words, the blowing agent and the parent material must be mixed, heated,
injected, etc while under pressure to stop the blowing agent and the
parent material from foaming until the blowing agent and the parent
material are (preferably, completely) inside a mold cavity, where the
blowing agent and the parent material experience a reduction in pressure
due to the larger volume of the mold cavity (when compared to the melt
channels, etc) and consequently the blowing agent and the parent material
"foam" within the confines of the molded part and (preferably) not foam
elsewhere in the melt conduit. In fact in some processes, a mold-clamp
force is reduced to allow the mold to partially blow open thereby further
reducing the pressure resisting foaming.

[0093]The mechanism 110 and the mechanism 114 each include: (i) respective
reciprocating screws (not depicted in FIG. 1, but depicted in FIG. 6 and
FIG. 7, by way of example) that are mounted in respective barrels
(depicted but not numbered) of the mechanism 110 and the mechanism 114,
and (ii) respective hoppers (depicted but not numbered) that are attached
to feed throats (depicted but not numbered) of their respective barrels.
The hopper associated with mechanism 110 is to receive solidified
particles (sometimes called "chips" or "blocks") of the alloy 112. The
hopper (that is, a receiving mechanism) associated with the mechanism 114
is to receive the spacing agent 116.

[0094]The system 100 also includes: (i) a stationary platen 102, and (ii)
a movable platen 103. The stationary platen 102 is configured to support
a stationary mold portion 108 of the mold 104. The movable platen 103 is
configured to: (i) move relative to the stationary platen 102 (by use of
a stroking actuator that is not depicted, but is known), and (ii) support
a movable mold portion 106 of the mold 104. The mold 104 is usually
supplied separately from the system 100. It is understood that the mold
104 is a component that wears down over time and is to be replaced as may
be required. The mold 104 has a mold body 111 that includes: (i) the
stationary mold portion 108, and (ii) the movable mold portion 106, which
in combination define a mold cavity 109 once the movable platen 103 is
made to move toward the stationary platen 102 sufficiently enough as to
abut the stationary mold portion 108 against the movable mold portion
106. The mold body 111 is used to moldably manufacture the article 124.
The stationary mold portion 108 defines a mold gate 107 that leads to the
mold cavity 109. The system 100 also includes a clamping mechanism 105
that is coupled to: (i) the stationary platen 102 (via tie bars 199), and
(ii) the movable platen 103. Specifically, the tie bars 199 are: (i)
connected to the stationary platen 102, and (ii) extend to the movable
platen 103. The tie bars 199 are lockably engageable and disengageable to
the movable platen 103 by locking mechanisms (not depicted) that are
known to those skilled in the art (and therefore will not be described in
the detailed description). The movable platen 103 may be used to house or
support the locking mechanisms at respective corners of the movable
platen 103. The tie bars 199 assist in coupling the clamping mechanism
105 to the stationary platen 102 when the locking mechanisms lock the tie
bars 199 to the movable platen 103. Once the platens 102, 103 are stroked
so as to close the mold 104, the locking mechanisms are engaged, the
clamping mechanism 105 may then be engaged so as to apply a clamp tonnage
(also called a clamping force) to the platens 102, 103 and in this manner
the clamp tonnage may be applied to the mold 104; since the process of
applying clamp tonnage is known to those skilled in the art, the process
is not further described in the detailed description. It will be
appreciated that the tie bars 199 will not be depicted in the remaining
FIGS. for the sake of simplifying the remaining FIGS. and the description
associated with the remaining FIGS.

[0095]The system 100 also includes a combining chamber 200 (hereafter
referred to as the "chamber 200"). The combining chamber 200 is
configured to receive the alloy 112 and the spacing agent 116. The alloy
112 and the spacing agent 116 are injectable under pressure into the
combining chamber 200. The alloy 112 and the spacing agent 116 are
combinable, at least in part, under pressure in the combining chamber
200. The combining chamber 200 is also configured to convey, under
pressure, the alloy 112 and the spacing agent 116 toward a mold 104. The
alloy 112 combined with the spacing agent 116 are solidifiably formable
into a molded-foamed-metallic article 124 in the mold 104. It will be
appreciated that the system 100 and the chamber 200 may be supplied or
sold separately or sold integrated.

[0096]According to a non-limiting variant, the chamber 200 is configured
to: (i) receive the alloy 112 that is injectable under pressure from the
mechanism 110, and (ii) receive the spacing agent 116 that is injectable
under pressure from the mechanism 114 so that, in effect, the alloy 112
and the spacing agent 116 combine, at least in part (under pressure), to
form a combined alloy 122 in the chamber 200. The combined alloy 122 is a
combination of the alloy 112 and the spacing agent 116. It is understood
that the combined alloy 122 is not necessarily a combination of two
alloys per se (that is, the combined alloy 122 may be a combination of
several alloys or just one alloy; the combined alloy includes at least
one alloy combined with at least one spacing agent). The combined alloy
122 may be referred to as an output alloy, but is hereafter referred to
as the "alloy 122". The chamber 200 is also configured to: (iii)
communicate, under pressure, the alloy 122 to the mold gate 107 that
leads to the mold cavity 109 that is defined by the mold 104 once the
platens 102, 103 are stroked together so as to close the mold 104. The
alloy 112 and the spacing agent 116 may be collectively referred to a
"plurality of inputs" or the "inputs", in that at least two or more
inputs may be combined in the chamber 200. Preferably (but not essential)
the chamber 200 includes a mixing element (not depicted) that is used to
improve the mixing (or combining) of the alloy 112 with the spacing agent
116 in the chamber 200.

[0097]The alloy 112 and spacing agent 116 are introduced into the
mechanism 110 and the mechanism 114, respectively. Once the alloy 112 is
introduced (in the form of solid chips, etc) to the mechanism 110, the
mechanism 110 converts the alloy 112 primarily into a thixotropic state
(sometimes referred to as the "semi-solid state") so that the alloy 112
contains a mixture of liquid and solid particles of globular shape, etc.
Alternatively, the mechanism 110 may convert the alloy 112 primarily into
the liquid state. It is understood that the mechanism 110 may condition
or process the alloy 112 so that the alloy 112 may exist primarily in:
(i) the liquid state, or (ii) the semi-solid state.

[0098]A technical effect of this arrangement is that the alloy 122 may be
manufactured having desired (or predetermined) characteristics (or
attributes) that are associated with the alloy 112 and with the spacing
agent 116. After combining or mixing the alloy 112 with the spacing agent
116, the alloy 122 is created. The alloy 122 solidifies in the mold
cavity 109 and is formed into the article 124. The article 124 is
removable from the mold 104 after: (i) the clamping mechanism 105 has
ceased applying the clamp tonnage between the movable platen 103 and the
stationary platen 102 (this includes application of a mold-break force to
the mold 104 by usage of a mold-break actuator, which is known to those
skilled in the art and not depicted), and (ii) the movable platen 103 has
been moved away from the stationary platen 102 so as to separate the
stationary mold portion 108 from the movable mold portion 106. The
article 124 may be: (i) ejected from the mold 104 by ejection mechanisms
(not depicted, but known to those skilled in the art), or (ii) may be
removed by a robot (not depicted, but known to those skilled in the art).

[0099]According to non-limiting variants, the chamber 200 includes a
combining valve 118. The combining valve 118 is configured to: (i) couple
to the mechanism 110, and (ii) couple to the mechanism 114. The chamber
200 also includes a conduit 120 that is configured to: (i) couple to the
combining valve 118, and (ii) couple to the mold gate 107 of the mold
104. The combining valve 118 is operable between: (i) a non-flow state,
and (ii) a flow state. In the non-flow state, the combining valve 118 is
configured to: (i) not receive the alloy 112 from the mechanism 110, and
(ii) not receive the spacing agent 116 from the mechanism 114. In the
flow state, the combining valve 118 is configured to: (i) receive the
alloy 112 from the mechanism 110, and (ii) receive the spacing agent 116
from the mechanism 114. The alloy 112 and the spacing agent 116 combine,
at least in part, to form the alloy 122 in the combining valve 118. The
conduit 120 is configured to: (i) receive the alloy 122 from the
combining valve 118, and (ii) communicate the alloy 122 to the mold gate
107 of the mold 104.

[0100]FIG. 2 depicts the schematic representation of the system 100
according to the second non-limiting embodiment. According to the second
non-limiting embodiment, the chamber 200 includes a combining valve 218
that is configured to: (i) couple to the mechanism 110, and (ii) couple
to the mechanism 114. The chamber 200 also includes a channel 208 that is
configured to couple to the combining valve 218. The chamber 200 also
includes a shooting pot valve 202 that is configured to couple to the
channel 208. The chamber 200 also includes a shooting pot 204 that is
configured to couple to the shooting pot valve 202. The shooting pot 204
includes a plunger 206 that is movable in the shooting pot 204. The
chamber 200 also includes a conduit 120 that is configured to couple to:
(i) the shooting pot valve 202, and (ii) the mold gate 107 of the mold
104. The combining valve 218 is operable between a non-flow state, and a
flow state. In the non-flow state, the combining valve 218 is configured
to: (i) not receive the alloy 112 from the mechanism 110, and (ii) not
receive the spacing agent 116 from the mechanism 114. In the flow state,
the combining valve 218 is configured to: (i) receive the alloy 112 from
the mechanism 110, and (ii) receive the spacing agent 116 from the
mechanism 114. The alloy 112 and the spacing agent 116 combine, at least
in part, to form the alloy 122 in the combining valve 218. The channel
208 is configured to receive the alloy 122 from the combining valve 218.
The shooting pot valve 202 is operable between a first valve state, and a
second valve state. In the first valve state, the shooting pot valve 202
is configured to not receive the alloy 122 from the channel 208. In the
second valve state, the shooting pot valve 202 is configured to receive
the alloy 122 from the channel 208. The shooting pot 204 is configured to
receive the alloy 122 from the shooting pot valve 202 once the shooting
pot valve 202 is placed in the second valve state. The shooting pot valve
202 is configured to disconnect the channel 208 from the shooting pot 204
once the shooting pot valve 202 is placed in the first valve state. The
conduit 120 is configured to: (i) receive the alloy 122 from shooting pot
valve 202 once the shooting pot valve 202 is placed in the first valve
state, and (ii) communicate the alloy 122 to the mold gate 107 of the
mold 104.

[0101]FIG. 3 depicts the schematic representation of the system 100
according to the third non-limiting embodiment. According to the third
non-limiting embodiment, the chamber 200 includes a combining valve 318
that is configured to: (i) couple to the mechanism 110, (ii) couple to
the mechanism 114, and (iii) couple to a shooting pot 204. The chamber
200 also includes a conduit 120 that is coupled to: (i) the combining
valve 318, and (ii) the mold gate 107 of the mold 104. The combining
valve 318 is operable between a first state, and a second state. In the
first state, the combining valve 318 is configured to: (i) receive the
alloy 112 from the mechanism 110, (ii) receive the spacing agent 116 from
the mechanism 114 (the alloy 112 and the spacing agent 116 combine, at
least in part, to form the alloy 122 in the combining valve 318), and
(iii) transmit the alloy 122 to a shooting pot 204. In the second state,
the combining valve 318 is configured to: (i) not receive the alloy 112
from the mechanism 110, (ii) not receive the spacing agent 116 from the
mechanism 114, and (iii) permit the shooting pot 204 to shoot the alloy
122 back into the combining valve 318. The conduit 120 is configured to:
(i) communicate the alloy 122, under pressure, from the combining valve
318 to the mold gate 107 once the combining valve 318 is placed in the
second state.

[0102]FIG. 4 depicts the schematic representation of the system 100
according to the fourth non-limiting embodiment. According to the fourth
non-limiting embodiment, the chamber 200 includes a combining valve 418
that is configured to: (i) couple to the mechanism 110, (ii) couple to
the mechanism 114, and (iii) couple to the mold gate 107 of the mold 104.
The combining valve 418 is operable between a first state, and a second
state. In the first state, the combining valve 418 is configured to: (i)
receive the alloy 112 from the mechanism 110, (ii) receive the spacing
agent 116 from the mechanism 114 (the alloy 112 and the spacing agent 116
combine, at least in part, in the combining valve 418 so as to form the
alloy 122), and (iii) communicate the alloy 122 to the mold gate 107 of
the mold 104. In the second state, the combining valve 418 is configured
to: (i) not receive the alloy 112 from the mechanism 110, and (ii) not
receive the spacing agent 116 from the mechanism 114.

[0103]FIG. 5 depicts the schematic representation of the system 100
according to the fifth non-limiting embodiment. According to the fifth
non-limiting embodiment, the chamber 200 includes a hot runner 402. The
hot runner 402 includes a manifold 404. The manifold 404 is configured to
support: (i) switching valve 408 and switching valve 428, (ii) a shooting
pot 412 and a shooting pot 432, and (iii) a combining valve 418. The
shooting pot 412 and the shooting pot 432 may collectively be known as
the "shooting pots 412, 432". The switching valve 408 and the switching
valve 428 may collectively be known as the "switching valves 408, 428".
The switching valve 408 and the switching valve 428 are coupled (via
conduits 406, 426 respectively) to the mechanism 110 and the mechanism
114 (respectively) so as to receive the alloy 112 and spacing agent 116
from the mechanism 110 and the mechanism 114 respectively (that is, once
the nozzle 190 and the nozzle 192 of the mechanism 110 and the mechanism
114, respectively, are made to contact the conduits 406, 426
respectively). Preferably, the nozzles 190, 192 are maintained in contact
(during operation of the system 100) with their respective conduits 406,
426. The nozzles 190, 192 are depicted offset from the conduits 406, 426
respectively for illustration purposes. The shooting pot 412 and the
shooting pot 432 are coupled to the switching valve 408 and the switching
valve 428 respectively (preferably via conduits). The combining valve 418
is coupled to the shooting pot 412 and the shooting pot 432 (via conduits
410, 430) and is also coupled to the mold gate 107 (via a conduit 420). A
hot-runner nozzle (not depicted in this non-limiting embodiment) may be
inserted in the conduit 420 if so required to control the release of
molding material (that is the alloy 122) into the mold cavity 109 of the
mold 104. According to a non-limiting variant, the switching valve 408
and switching valve 428 are "on/off" valves that are switchable (or
operable) between a non-flow state and a flow state. According to another
non-limiting variant, the switching valve 408 and the switching valve 428
are "on/off/variable-flow" valves that are switchable (or operable)
between: (i) a non-flow state, (ii) a full-flow state and (iii) a
partial-flow state. According to yet another non-limiting variant, the
combining valve 418 is an "on/off" valve that is switchable (or operable)
between: (i) a non-flow state, and (ii) a flow state. According to yet
another non-limiting variant, the combining valve 418 is an
"on/off/variable-flow" valve that is switchable (or operable) between:
(i) a non-flow state, (ii) a full-flow state, and (iii) a partial-flow
state.

[0104]The shooting pot 412 and the shooting pot 432, include: (i) a
pressure chamber 414 and a pressure chamber 434 respectively, (ii) an
accumulation chamber 416 and an accumulation chamber 436 respectively,
and (iii) a piston 417 and a piston 437 respectively that are each
slidably movable within their respective accumulation chambers 416, 436.
The pressure chamber 414 and the pressure chamber 434 may collectively be
known as the "pressure chambers 414, 434". The pressure chambers 414, 434
are fillable with a pressurizable fluid, such as compressed air, or can
be actuated by a remote drive not shown. If hydraulic oil is used, care
must be used because the temperatures needed for processing metal alloys
may cause hydraulic oil to ignite. It will be appreciated that the
shooting pot 412 and the shooting pot 432 may be actuated by electrical
actuators (not depicted), etc. In operation, initially the combining
valve 418, the switching valve 408 and the switching valve 428 are placed
in the non-flow state. The pressure chamber 414 and the pressure chamber
434 are de-pressurized so as to permit respective pistons 417, 437 to
retract (that is, to be movable). The mechanism 110 and the mechanism 114
are configured to process and prepare the alloy 112 and spacing agent
116, respectively. After the mechanism 110 and the mechanism 114 are each
ready to inject or shoot the alloy 112 and the spacing agent 116
respectively, the combining valve 418 remains in the non-flow state, and
the switching valve 408 and the switching valve 428 are placed in the
flow state, and then the mechanisms 110, 114 inject the alloy 112 and the
spacing agent 116, respectively, into the conduits 406, 426 respectively
so that (in effect) the alloy 112 and spacing agent 116 may be injected,
under pressure, into the accumulation chambers 416, 436 of the shooting
pots 412, 432 respectively; as a result, the pistons 417, 437 are moved
into the pressure chambers 414, 434 respectively so as to displace the
pressurizable fluid out from the pressure chambers 414, 434 respectively.
Once the mechanism 110 and the mechanism 114 have completed their
injection cycle, the switching valve 408 and the switching valve 428 are
placed in the non-flow state, the combining valve 418 is placed in the
flow state (either full-flow or partial flow, etc, as may be required to
achieve a desired combination of the alloy 112 and spacing agent 116),
and the pressure chambers 414, 434 are pressurized (that is, filled with
the pressurizable fluid); as a result, the pistons 417, 437 are moved
into their respective accumulation chambers 416, 436 respectively so as
to inject or push the alloy 112 and the spacing agent 116 respectively
into the combining valve 418. Then the alloy 112 and spacing agent 116
become combined, at least in part in the combining valve 418, to form the
alloy 122. The alloy 122 then is pushed, under pressure, through the
conduit 420 into the mold gate 107. The combining valve 418 may be used
or arranged so that a desired ratio of the alloy 112 and spacing agent
116 may be realized. The switching valve 408 and the switching valve 428
may be used so as to permit a desired amount of flow of the alloy 112 and
of the spacing agent 116 into the accumulation chambers 416, 436
respectively (as may be required). It will be appreciated that a single
drop (that is, the conduit 420) is depicted, and that the non-limiting
embodiment may be modified to operate with a plurality of drops that: (i)
all lead into a single mold cavity (as depicted), or (ii) lead into
separate mold cavities (not depicted).

[0105]FIG. 6 depicts the schematic representation of the system 100
according to the sixth non-limiting embodiment. According to the sixth
non-limiting embodiment, the manifold 404 is configured to support: (i)
the shooting pot 412 and the shooting pot 432, and (iii) the combining
valve 418. The shooting pots 412, 432 are coupled to the mechanisms 110,
114 (respectively) so as to receive the inputs from the mechanisms 110,
114 respectively. The combining valve 418 is coupled to: (i) the shooting
pots 412, 432, and (ii) the mold gate 107. The switching valves 408, 428
of the fifth non-limiting embodiment are not used in the sixth
non-limiting embodiment. In operation, the combining valve 418 is
operated in the non-flow state, and the mechanism 110 and the mechanism
114 accumulate their respective shots of alloys and then inject the alloy
112 and spacing agent 116 respectively into the accumulation chambers
416, 436 (so that in effect, the shots of the alloy 112 and the spacing
agent 116 are transferred into the accumulation chambers 416, 436). Once
the shots are received in the accumulation chambers 416, 436, (i) screws
292, 294 of the mechanisms 110, 114 respectively (the screws 292, 294 are
equipped with non-return valves) maintain their positions so as to
prevent flow of the alloy 112 and the spacing agent 116 back into the
mechanisms 110, 114 respectively, and (ii) the combining valve 418 is
placed in the flow state. The pressure chamber 414 and the pressure
chamber 434 are pressurized so as to move their respective pistons 417,
437 into the accumulation chambers 416, 436 respectively so as to inject
or push the alloy 112 and the spacing agent 116 from the accumulation
chambers 416, 436 respectively into the combining valve 418. A hot-runner
nozzle (not depicted) may be inserted in the conduit 420 if so required
to control the release of molding material into the mold cavity 109 of
the mold 104. It will be appreciated that a single drop (that is, conduit
420) is depicted, and that the non-limiting embodiment may be modified to
operate with a plurality of drops that lead into the mold cavity 109 (or
that lead into separate mold cavities (not depicted).

[0106]FIG. 7 depicts the schematic representation of the system 100
according to the seventh non-limiting embodiment. According to the
seventh non-limiting embodiment, the mold 104 defines the mold cavity 109
and the mold cavity 509. The mold cavities 109, 509 may be known
collectively as mold cavities 109, 509. Associated with each of the mold
cavities 109, 509 is the mold gate 107 and a mold gate 507, respectively,
that each lead to the mold cavity 109 and the mold cavity 509
respectively. The manifold 404 supports the nozzles 504, 506 (sometimes
referred to as "hot-runner nozzles") that are coupled (via conduit 502)
to the combining valve 418, and also coupled to respective mold gates
107, 507. In operation, the alloy 112 and spacing agent 116 combine to
form the alloy 122 (at least in part) in the combining valve 418, the
conduit 502, and the nozzles 504, 506.

[0107]FIG. 8 depicts the schematic representation of the metal
injection-molding process 10 (hereafter referred to as the "process 10")
according to the eighth non-limiting embodiment. Generally, the process
10 includes injecting, under pressure, the alloy 112 and the spacing
agent 116 into the mold 104. According to a non-limiting variant, the
process 10 includes: (i) a receiving operation 12, (ii) a heating
operation 14, (iii) a combining operation 16 and (iv) an injecting
operation 18. The receiving operation 12 includes receiving a
solidified-metallic alloy 113 and the spacing agent 116. The heating
operation 14 includes heating the solidified-metallic alloy 113
associated with the receiving operation 12 above a solidus temperature of
the solidified-metallic alloy 113 so that the solidified-metallic alloy
113 may become the alloy 112. The combining operation 16 includes
combining the alloy 112 associated with the heating operation 14 with the
spacing agent 116 associated with the receiving operation 12. The
injecting operation 18 includes injecting, under pressure, the alloy 112
and the spacing agent 116 into the mold 104. At a minimum, the alloy 112
is heated above a solidus temperature of the alloy 112 but below a
liquidus temperature of the alloy 112 (so that the alloy 112 may exist in
a semi-solid state). Optionally, the alloy 112 is heated above a liquidus
temperature of the alloy 112 (so that the alloy 112 exists primarily in a
liquid state). The alloy 112 includes an AZ91D alloy, and the liquidus
temperature of the AZ91D alloy is nominally 595 degrees Centigrade
(° C.). The alloy 112 includes a zinc alloy. According to
non-limiting variants: (i) the alloy 112 includes a magnesium alloy,
and/or (ii) an aluminum alloy. A material input 2 is used by the process
10, and the material input includes at least the alloy 112 and/or the
spacing agent 116. The article 124 is made by the process 10. The system
100 of FIG. 1 is operable according to the process 10 of FIG. 8.

[0108]FIG. 9 depicts a schematic representation of the metal
injection-molding system 500 operable according to the process 10 of FIG.
8. The metal injection-molding system 500 includes: (i) receiving means
512, (ii) heating means 514, (iii) combining means 516 and (iv) injection
means 518. The receiving means 512 is configured to implement a receiving
operation 12 including receiving the solidified-metallic alloy 113 and
the spacing agent 116. The heating means 514 is configured to implement a
heating operation 14 including heating the solidified-metallic alloy 113
associated with the receiving operation 12 above the solidus temperature
of the solidified-metallic alloy 113 so that the solidified-metallic
alloy 113 may become (or may be transformed into) the alloy 112. The
combining means 516 is configured to implement a combining operation 16,
including combining the alloy 112 associated with the heating operation
14 with the spacing agent 116 associated with the receiving operation 12.
The injection means 518 is configured to implement an injecting operation
18, including injecting, under pressure, alloy 112 and the spacing agent
116 into the mold 104.

[0109]The description of the non-limiting embodiments provides examples of
the present invention, and these examples do not limit the scope of the
present invention. It is understood that the scope of the present
invention is limited by the claims. The non-limiting embodiments
described above may be adapted for specific conditions and/or functions,
and may be further extended to a variety of other applications that are
within the scope of the present invention. Having thus described the
non-limiting embodiments, it will be apparent that modifications and
enhancements are possible without departing from the concepts as
described. It is to be understood that the non-limiting embodiments
illustrate the aspects of the invention. Reference herein to details of
the illustrated embodiments is not intended to limit the scope of the
claims. The claims themselves recite those features regarded as essential
to the present invention. Preferable embodiments of the present invention
are subject of the dependent claims. Therefore, what is to be protected
by way of letters patent are limited only by the scope of the following